ES2846753T3 - Ultrasonic Inspection Using Incidence Angles - Google Patents

Abstract

Method comprising: sending (600) an ultrasonic signal to a structure (208) at an angle of incidence (223) from an array of ultrasonic transducers (220); detecting (602) a response signal (242) at the ultrasonic transducer array (220) to form a received response, the response signal (242) being reflected from the structure (208) in response to the ultrasonic signal sent to the structure (208); identifying a first location (236) of the ultrasonic transducer array (220), wherein the first location (236) is an estimated receiving location for a response signal (242) reflected from a rear surface of the structure (208 ); determining a second location (238) of the ultrasonic transducer array (220), wherein the second location (238) is an estimated receiving location for a response signal (240) reflected by an inconsistency within the structure (208 ); configuring the ultrasonic transducer array (220) such that the inactive elements (232) are located at the second location (238); and configuring the number of idle elements (232) to decrease an amplitude of the response signal (242) reflected from the rear surface of the frame (208) when the inconsistency is present.

Description

DESCRIPTION

Ultrasonic Inspection Using Incidence Angles

Background

The present disclosure relates generally to ultrasonic inspection and, in particular, to a method and apparatus for identifying undesirable conditions in an object using ultrasonic inspection. Even more particularly, the present disclosure relates to a method and apparatus for ultrasonic inspection using signals with an angle of incidence.

Aircraft are being designed and manufactured with increasing percentages of composite materials. Some aircraft may have more than fifty percent of their main structure made from composite materials. Composite materials can be used in aircraft to decrease the weight of the aircraft. This weight reduction can improve payload capabilities and fuel efficiency. Additionally, composite materials can provide a longer service life for various aircraft components.

Composite materials can be strong, lightweight materials created by combining two or more different components. For example, a composite material can include fibers and resins. The fibers and resins can be combined to form a cured composite material.

In particular, key components, such as wings and fuselage skins, can be constructed of composite materials such as, without limitation, a composite laminate structure. With more and more basic structures made from laminated composite structures, methods and techniques are needed more than ever to ensure that these components meet quality requirements.

The presence of foreign materials or debris within a composite component is an example of a known undesirable condition that can occur during processing to create composite components. Today, a lot of time, effort and money can be invested in non-destructive measurement systems designed to detect and quantify debris in composite components, such as those made using laminated carbon structures. Other examples of undesired conditions include, for example, porosity within the component and delamination.

Ultrasonic testing involves sending ultrasonic pulse waves to an object to detect undesirable conditions or to characterize materials. In ultrasonic testing, one or more ultrasound transducers are passed over an object being inspected. Typically, the transducers are separated from the object under test by a coupling material. This coupling material can be, for example, a liquid such as oil or water. Coupling material is used to prevent signal loss. In this way, unwanted conditions can be detected.

However, debris identification can be difficult using a transducer for ultrasonic testing. Furthermore, ultrasonic inspection using more than one ultrasonic transducer can be undesirably difficult to control or implement.

Therefore, it would be desirable to have a method and apparatus that take into account at least some of the problems discussed above, as well as other possible problems.

In summary, WO 2010/026253 A1 discloses a "non-destructive ultrasonic test method in which at least one ultrasonic pulse is emitted towards a work piece under test by means of at least one ultrasonic transmitter, the The ultrasonic pulse is reflected from boundary surfaces within the workpiece, the reflected ultrasound is received by at least one ultrasonic receiver and the associated signals are evaluated, the ultrasound penetrating a damping block that is arranged between the workpiece and the transmitter or receiver. Said method is characterized in that it includes at least one step to determine the speed of sound in the damping block by means of a matrix type probe comprising selectively controllable transducers; In said step, at least a first transducer of the matrix-type probe is used as a transmitter of at least one ultrasonic pulse, while at least one second transducer of the matrix-type probe is used as a receiver of the ultrasonic pulse and the speed of sound in the damping block is determined at least by measuring the ultrasound propagation time along the shortest ultrasound distance between the respective transducers that are placed at a distance from each other ".

In summary, JP 2007 322350 discloses “an ultrasonic test to improve efficiency in detecting defects of an object under inspection and to accurately assess the existence and size of a defect of the object under inspection. . An ultrasonic test using a phased array method is performed on an inspected object part of the inspected object using a phased array probe ”.

In summary, EP 1043584 A1 discloses "a method and apparatus for ultrasonic detection of defects of a weld part using a matrix probe, the wedge supporting the matrix probe such that the ultrasonic beams emitted from the matrix probe are at predetermined refractive angles. A welded part is sectorally scanned in the direction of the depth of the welded part. A sector scan angle stage is set so that the scan beams overlap each other in order to carry out flaw detection using ultrasonic waves so that each scan line focus point is arranged on the welded part ”.

In summary, EP 2182352 A2 states that “an object of the present invention is to provide an apparatus and a method for ultrasonic testing that enables high resolution and high S / N ratio test results to be obtained through imaging by actuation of a number of piezoelectric elements, the apparatus and method comprising a smaller number of pulse generators and receivers compared to the number of elements that make up a matrix transducer. An information sensor 102F establishes a plurality of groups of piezoelectric elements (groupings of elements) used for transmission and a plurality of groups of piezoelectric elements (groupings of elements) used for reception of the plurality of piezoelectric elements that make up a transducer of ultrasonic array 101. A computer 102G performs the steps of: transmitting an ultrasonic wave from the array of elements set for transmission and storing an ultrasonic wave received by the array of elements set for reception as a first reception signal; repeating a procedure for changing the item pool set for transmission and the item pool set for reception and storing another first reception signal; summarizing the plurality of first reception signals obtained by repeating the same procedure to obtain a second reception signal; and displaying the second reception signal with reference to the center position of the sensor on a display unit 103 ".

In summary, EP 2124045 A1 states that "the present invention has a structure capable of detecting the penetrating element of the dispersed type having oxides, each having the size of several mm poorly and widely dispersed. Specifically, the structure includes a wave transmission unit 6 for transmitting an ultrasonic wave to the welded surface of the welded part 2 in an axial direction of pipe 1 so that the beam width of a transmission beam 8 is input into a interval between 0.5 mm and 2.5 mm, and a wave receiving unit 7 to receive at least a part of the reflection wave (receiving beam 9) on the welded surface. The wave transmission unit 6 and the wave reception unit 7 include transmission / reception units formed by different groups of transducer elements in at least one or more matrix probes 5 arranged in the circumferential direction of the pipe ".

In summary, EP 2124046 A1 states that “according to the present invention, penetration elements can be suitably determined as defects. In particular, a welded zone 2 of a pipe 1 is subjected to ultrasonic flaw detection at least in an axial direction of the pipe, and the quality of the pipe is evaluated using observed values in units of a predetermined zone in a thickness direction of pipe and pipe axial direction. The length of one side of the predetermined zone is an ultrasound beam width or more and a pipe thickness or less. The quality of the pipe can be evaluated while moving the predetermined zone in the pipe axial direction by using an average value of the values observed within the predetermined zone. The length of one side of the predetermined area can be made of an ultrasound beam width or more and a pipe thickness or less ".

Summary

The present invention is set forth in the independent claims, with some optional features set forth in the claims dependent thereon.

Brief description of the drawings

The novel features considered characteristic of the illustrative embodiments are set forth in the appended claims. However, illustrative embodiments, as well as a preferred mode of use, objectives, and additional features thereof, will be better understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the drawings. attachments, in which:

Figure 1 is an illustration of a production environment in which an illustrative embodiment may be implemented;

Figure 2 is an illustration of a production environment in the form of a block diagram in accordance with an illustrative embodiment;

Figure 3 is an illustration of inspection equipment within a production environment in accordance with an illustrative embodiment;

Figure 4 is an illustration of a cross-sectional view of inspection equipment within a production environment in accordance with an illustrative embodiment;

Figure 5 is an illustration of a method for identifying a first location in accordance with an illustrative embodiment; Figure 6 is an illustration of a process for inspecting a structure in accordance with an illustrative embodiment;

Figure 7 is a block diagram illustration of a data processing system in accordance with an illustrative embodiment;

Figure 8 is an illustration of an aircraft manufacturing and servicing method in the form of a block diagram in accordance with an illustrative embodiment; Y

Fig. 9 is an illustration of an aircraft in the form of a block diagram in which an illustrative embodiment may be implemented.

Detailed description

Different illustrative embodiments recognize and take into account different considerations. For example, the different illustrative embodiments recognize and take into account that traditionally the same ultrasonic transducer can send normal ultrasonic signals with respect to the object and receive ultrasonic signals. The different illustrative embodiments also recognize and take into account that when using the same ultrasonic transducer and normal signals with respect to the object, the reflection from the debris can closely match the reflection from the material. As a result, the identification of wastes can be difficult.

Similarly, the different illustrative embodiments recognize and take into account that an ultrasonic transducer can be used to transmit the ultrasonic signals across the surface using an angled wedge while an independent receiver detects a response from the other surface after scroll through a medium. The different illustrative embodiments recognize and take into account that the use of more than one ultrasonic transducer may require alignment and may be greater than the use of the same transducer, increasing the difficulty of control and implementation.

Additionally, the different illustrative embodiments recognize that by not detecting response signals reflected by inconsistencies, the signal-to-noise ratio can be increased. Different illustrative embodiments also recognize that sensitivity can be increased by not detecting response signals reflected by inconsistencies. Different illustrative embodiments recognize and take into account that by not detecting response signals reflected by inconsistencies, inspection time can be reduced. The different illustrative embodiments further recognize and take into account that, by increasing sensitivity, more complex structure inspections can be performed.

Thus, the various illustrative embodiments provide a method and apparatus for identifying undesirable conditions in an object using ultrasonic inspection. In an illustrative example, a signal can be sent to a structure at an angle of incidence from a transducer array. A response signal reflected from the frame in the transducer array in response to the signal sent to the frame can be detected to form a received response.

Now, with reference to the figures, and in particular, with reference to Figure 1, an illustration of a production environment according to an illustrative embodiment is depicted. In this illustrative embodiment, production environment 100 has structure 102. Structure 102 can be comprised of a number of different materials. These materials can include, for example, without limitation, plastic, metal, composite, ceramic, and other types of suitable materials. As shown, structure 102 can be a composite panel.

The production environment 100 also has an inspection team 104, an inspection team 106, and an inspection team 108. As shown, the inspection team 104 can be moved along the structure 102 by the articulated arm 110. As shown, inspection equipment 106 can be moved along structure 102 by a tracked robot 112. As shown, inspection equipment 108 can be moved along structure 102 by a human operator 114.

Each of inspection equipment 104, inspection equipment 106, and inspection equipment 108 may be associated with a water source to provide a coupling material for inspection. As shown, inspection equipment 104 can receive water from utility lines associated with link arm 110. As shown, inspection equipment 106 and inspection equipment 108 can be coupled to a utility source 116 using respective utility conduits.

This illustration of the production environment 100 is provided for the purpose of illustrating an environment in which the various illustrative embodiments can be implemented. The illustration of the production environment 100 in FIG. 1 is not intended to imply architectural limitations as to how the different illustrative embodiments can be implemented. For example, only one of the human operator 114, the tracked robot 112, and the articulated arm 110 may be present in the production environment 100. Also, the structure 102 does not have to be a composite panel. In an illustrative example, frame 102 can be a metal panel. In another illustrative example, structure 102 can be a composite reinforcement. In yet another illustrative example, frame 102 may be an aircraft fuselage section. Still further, frame 102 need not be supported by a table as shown.

Now referring to Fig. 2, an illustration of a production environment is depicted in the form of a block diagram according to an illustrative embodiment. The production environment 200 may be an implementation of the production environment 100 of Figure 1.

Production environment 200 comprises a controller 204, inspection equipment 206, and frame 208. Controller 204 may be configured to control inspection of frame 208 by inspection equipment 206 using a number of parameters 210. The number of Parameters 210 may comprise at least one of amplitude, a number of pulses, angle of incidence, or other suitable parameters. As used herein, the term "at least one of", when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one of each may be required. one of the items on the list. For example, "at least one of item A, item B, and item C" may include, without limitation, item A, item A, and item B, or item B. This example may also include item A, item item B and item C or item B and item C. In other examples, "at least one of" may be, for example, without limitation, two from item A, one from item B, and ten from item C; four of article B and seven of article C; and other suitable combinations. The item can be a particular object, thing, or category. In other words, at least one of means that any combination of items and a number of items from the list can be used, but not all items from the list are required.

Additionally, controller 204 can be used to configure inspection equipment 206. Controller 204 can be implemented in software, hardware, firmware, or a combination thereof. When using software, the operations performed by controller 204 can be implemented in program code configured to run on a processor unit. When using firmware, operations performed by controller 204 can be implemented in program code and data and stored in persistent memory for execution in a processor unit. When hardware is used, the hardware may include circuits that work to perform the operations in the controller 204.

Inspection equipment 206 is configured to inspect structure 208. Structure 208 comprises material 212, a number of inconsistencies 214, and thickness 216. Material 212 has material velocity 218. Material velocity 218 is a measure of the velocity at which the signals propagate in the material 212.

Inspection team 206 can identify the number of inconsistencies 214 through inspection of structure 208. As used herein, "a number of" items means one or more items. For example, an inconsistency number 214 means one or more inconsistencies. The number of inconsistencies 214 comprises a number of undesirable conditions within the structure 208. The number of inconsistencies 214 can include foreign material, debris, voids, or other suitable undesirable conditions.

Inspection equipment 206 can send signals through coupling material 222 and to frame 208. Coupling material 222 can be used to increase the transmission of the number of signals 219 to frame 208. Coupling material 222 has a thickness of 224 and a material velocity 226. The material velocity 226 is a measure of the speed at which signals propagate in the coupling material 222. In some illustrative examples, the material velocity 226 may be different from the material velocity 218. The difference between material velocity 226 and material velocity 218 is less than the difference between air velocity and material velocity 218. Consequently, coupling material 222 reduces the reflection that would occur if air were present. between transducer array 220 and frame 208. Coupling material 222 can be one of an oil, a gel, a hydrogel, water, or other materials. suitable. Coupling material 222 can be selected based on material speed 218, material speed 226, idle with material 212, cost, or other suitable parameters.

Inspection equipment 206 may inspect frame 208 by sending a number of signals 219 to frame 208 using transducer array 220. Transducer array 220 is held within cover 225 and comprises a plurality of elements 228. The plurality of items 228 comprises a number of sending items 230, a number of idle items 232, and a number of receiving items 234. Controller 204 may configure inspection equipment 206 by configuring each of the plurality of items. 228 of the transducer array 220 to be one of the number of send elements 230, the number of idle elements 232, or the number of receive elements 234. Controller 204 may configure the plurality of elements 228 based on at least one of the angle of incidence 223 of the number of signals 219 to be sent, the thickness 216, the material speed 218 of the material 212, the thickness 224 of the matte coupling material 222, material velocity 226 of coupling material 222, or any other suitable parameter. In some illustrative examples, controller 204 may configure transducer array 220 based on a second location 238 and a first location 236.

The number of sending elements 230 is configured to send a number of signals 219 to the frame 208. In some illustrative examples, the transducer array 220 can send a number of signals 219 at the angle of incidence 223. The angle of incidence 223 it can be any desirable angle as long as the response signal 242 reflected from the rear surface of the structure 208 reaches the transducer array 220. In an illustrative example, the angle of incidence 223 can be 6 degrees.

In some illustrative examples, the number of sending elements 230 can send a number of signals 219 at the angle of incidence 223 using electronic time delay beam steering or other suitable methods. By sending the number of signals 219 from transducer array 220 at angle of incidence 223 using electronic time delay beam steering, transducer array 220 can remain parallel to frame 208.

The number of idle elements 232 are not configured to send or receive signals. As a result, responses reaching the number of inactive elements 232 will not be detected. By not detecting the response signal 240 reflected by the number of inconsistencies 214, the ultrasonic inspection can be improved.

In some illustrative examples, the number of inactive items 232 may be located in the second location 238. In some illustrative examples, only some inactive items of the number of inactive items 232 may be located in the second location 238. In some illustrative examples, the second location 238 of transducer array 220 based on at least one of angle of incidence 223, thickness 224, thickness 216, material velocity 226, and material velocity 218. In some illustrative examples, the second location 238 may be an estimated reception location of the response signal 240 reflected by an inconsistency of the number of inconsistencies 214 within frame 208. In some illustrative examples, the second location 238 may be determined based on processing characteristics 239 of frame 208. Examples of processing characteristics 239 may be a possible chemical composition of the number of inconsistencies 214 during processing of framework 208, layers of framework 208 more susceptible to inconsistencies during processing of framework 208, and other suitable processing characteristics.

The number of inactive elements 232 can increase the sensitivity of the ultrasonic inspection to detect inconsistencies 214. If the response signal 240 reaches the number of inactive elements 232, the response signal 240 will not be detected. By not detecting the response signal 240 reflected by the number of inconsistencies 214, the ultrasonic inspection can be improved.

Ultrasonic inspection can be improved by decreasing the amplitude of the response signal 242 relative to the number of inconsistencies 214. In other words, the amplitude of the response signal 242 will be greater when an inconsistency of the number of inconsistencies 214 is not present in the area under test of frame 208. The amplitude of the response signal 242 will be less when an inconsistency of the number of inconsistencies 214 is present in the area under test of frame 208.

In some illustrative examples, the number of inactive elements 232 is configured to decrease an amplitude of the response signal 242 reflected from the rear surface of the structure 208 when an inconsistency of the number of inconsistencies 214 is present. In some illustrative examples, the angle of incidence 223 is configured to decrease an amplitude of the response signal 242 reflected from the rear surface of the frame 208 when an inconsistency is present.

An inconsistency in the number of inconsistencies 214 can be identified by subtracting the amplitude of the response signal 242 from a desired value. The desired value may be the amplitude of a response signal reflected from the rear wall of frame 208 when an inconsistency of the number of inconsistencies 214 is not present.

By not detecting the response signal 240 reflected by the number of inconsistencies 214, the difference in amplitude can be greater. Furthermore, by not detecting the response signal 240 reflected by the number of inconsistencies 214, the difference in amplitude can be more easily identified. Furthermore, by not detecting the response signal 240 reflected by the number of inconsistencies 214, the difference in amplitude can be identified more quickly.

Therefore, by increasing the loss of signal relative to the presence of an inconsistency of the number of inconsistencies 214, the sensitivity of the ultrasonic inspection with respect to the number of inconsistencies 214 can be increased. By increasing the sensitivity, inspection times can be reduced. Still further, increased sensitivity can allow inspection of more complex structures.

The number of receiving elements 234 is configured to detect the response signal 242 reflected from the frame 208 in response to a signal of the number of signals 219 sent to the frame 208 to form a received response. The transducer array 220 can be configured so that the number of receiving elements 234 is located at the first location 236. The first location 236 can be located at an estimated receiving location for the response signal 242 reflected from the rear surface of the structure 208. First location 236 of transducer array 220 can be identified based on at least one of angle of incidence 223, thickness 224, thickness 216, material velocity 226, or material velocity 218.

In some illustrative examples, the second location 238 may be determined based on the first location 236. In these illustrative examples, the second location 238 may be the area of the transducer array 220 between the number of send elements 230 and the first location 236. .

As shown in FIG. 2, by sending the number of signals 219 at the angle of incidence 223, the response signal 240 and the response signal 242 return at non-normal angles. Due to the location of the number of inconsistencies 214 within the structure 208, the response signal 240 reflected by the number of Inconsistencies 214 will reach the transducer array 220 at a different location than the response signal 242. By sending the number of signals 219 at the angle of incidence 223, the inspection team increases the difference in the distance traveled by the response signal 240. and the response signal 242. This distance difference is greater than if the number of signals 219 had been sent in a normal direction to the structure 208. Consequently, the difference between the time response signal 240 is received and the signal Received time response 242 also increases when compared to the number of send signals 219 in a direction normal to frame 208. This increase in time difference can also increase one in sensitivity and signal-to-noise ratio.

The illustration of the production environment 200 in FIG. 2 is not intended to imply physical or architectural limitations as to how an illustrative embodiment may be implemented. Other components may be used in addition to or in place of those illustrated. Some components may be unnecessary. Also, blocks are present to illustrate some functional components. One or more of these blocks can be combined, split, or combined and split into different blocks when implemented in an illustrative embodiment.

For example, in some illustrative examples, the transducer array 220 may not have a second location 238. The number of idle elements 232 may be located in the transducer array 220 based on not being one of the number of send elements 230 or the number of reception elements 234.

Now referring to Fig. 3, an illustration of inspection equipment is depicted within a production environment according to an illustrative embodiment. Figure 3 is a detailed view of inspection equipment 104 in frame 102 of Figure 1.

As shown, link arm 110 supports inspection equipment 104. Link arm 110 can move inspection equipment 104 through frame 102. Inspection equipment 104 has a cover 302. Cover 302 can be pressed against structure 102, since inspection team 104 moves through structure 102.

Now referring to Fig. 4, an illustration of a cross-sectional view of inspection equipment within a production environment is depicted in accordance with an illustrative embodiment. Figure 4 is a cross-sectional view of inspection equipment 104 of frame 102 of Figure 1 and Figure 3, taken along lines 4-4 of Figure 3.

Inspection equipment 104 is configured to detect inconsistencies 412 in structure 102. Inspection equipment 104 has a cover 302 and a transducer array 402. Transducer array 402 has a plurality of elements 404. Transducer array 402 is configured to send signals to structure 102. Structure 102 has a front surface 403, a rear surface 405, a plurality of layers of material 406, and an inconsistency 412. The array of transducers 402 can send signals through the coupling material 408 and front surface 403 to frame 102. As shown, coupling material 408 may comprise water.

The plurality of elements 404 may be a physical implementation of the plurality of elements 228 of FIG. 2. The plurality of elements 404 comprises inactive elements 414, sending elements 416, inactive elements 418, receiving elements 420 and inactive elements 422. The The plurality of elements 404 may comprise any number of elements. As depicted, the plurality of elements 404 comprises 64 elements. By increasing the number of elements of the plurality of elements 404 of the transducer array 402, the transducer array 402 can achieve higher resolution. By decreasing the number of elements of the plurality of elements 404 of the transducer array 402, the transducer array 402 can achieve a lower resolution.

As depicted, the inactive elements 418 are located at the second location 424 of the transducer array 402. The receiving elements 420 are located at the first location 426.

In operation, the sending elements 416 can send the signal 428 at an angle of incident through the coupling material 408 and into the structure 102. As shown, part of the signal 428 will reflect the inconsistency 412 as a response signal 430 As shown, the response signal 430 will reach the transducer array 402 at the inactive elements 418. Consequently, the response signal 430 will not be detected by the transducer array 402.

The remainder of the signal 428 may continue to the back surface 405 of the frame 102. The remainder of the signal 428 may be reflected from the back surface 405 as a response signal 432. As shown, the response signal 432 will reach the transducer array 402 at receiving elements 420. Accordingly, the response signal 432 will be detected by transducer array 402.

By not detecting the response signal 430, the sensitivity of the inspection by the transducer array 402 may be greater than an inspection using signals normal to the frame 102. Increasing the sensitivity can result in faster evaluation times. Additionally, increased sensitivity may allow the 402 transducer array to inspect more complex structures than could be inspected using normal signals to the structure. Still further, by not detecting the response signal 430, the signal-to-noise ratio of the inspection by the transducer array 402 can be higher than by using signals normal to the structure 102.

In Figure 1 and Figures 3-4, illustrations of an inspection system according to an illustrative embodiment are depicted. The different components shown in Figure 1 and Figures 3-4 for inspection equipment 104 can be combined with the components of Figure 2, used with the components of Figure 2, or a combination of both. Additionally, some of the components in these figures may be illustrative examples of how the components shown in block form in Figure 2 can be implemented as physical structures.

Now referring to FIG. 5, an illustration of a method for identifying a first location in accordance with an illustrative embodiment is depicted. As depicted, FIG. 5 is an illustration depicting a computation process for the first location 236 of FIG. 2.

Test environment 500 comprises transducer array 502, coupling material 504, and frame 506. Frame 506 has a front surface 508 and a rear surface 518. As shown, coupling material 504 has a thickness of 510 and a material speed 512. As shown, the structure 506 has a thickness 514 and a material speed 516.

To identify the first location 532, a calculation can be based on the signals that are sent from the third location 520. The signal 521 can be sent at the angle of incidence 522. The signal 521 can travel the distance 524 before reaching the front surface 508.

Distance 524 can be determined by any suitable method. In an illustrative example, distance 524 can be determined by the following formula: X1 = Y1 * tan a, where X1 represents distance 524, Y1 represents thickness 510, and a represents angle of incidence 522.

After reaching the front surface 508, a sign angle 521 with respect to the front surface 508 may change from the angle of incidence 522 to the angle 526. The sign angle 521 may change at the front surface 508 as a result of the difference in value between material velocity 512 and material velocity 516. Angle 526 can be determined by any suitable method. In an illustrative example, angle 526 can be determined by the following formula: p = arc sine ((v2 / v1) * sine a), where v2 represents material velocity 516, v1 represents material velocity 512, and p represents the angle 526.

Signal 521 can travel distance 528, since signal 521 travels from front surface 508 to rear surface 518. Distance 528 can be determined by any suitable method. In an illustrative example, distance 528 can be determined using the following formula: X2 = Y2 * tan p, where X2 represents distance 528 and Y2 represents thickness 514.

Upon reaching the back surface 518, the signal 521 can be reflected from the back surface 518. The signal response 529 produced can be substantially the same angle as the angle 526. The response from the signal 529 can then travel through the structure 506 toward the front surface 508. After reaching the front surface 508, the signal response angle 529 may change. The signal response angle 529 may change at the front surface 508 as a result of the difference in value between the material speed 512 and the material speed 516. The signal response angle 529 can be substantially the same angle as the angle incidence 522.

Signal response 529 can then travel through coupling material 504 to transducer array 502. Signal response 529 can then reach structure 506 at first location 532. First location 532 can be described as a receive location estimated for a response reflected from the back surface 518 of structure 506.

Distance 530 comprises a total cross distance from third location 520 to first location 532. Distance 530 can be determined by any suitable method. Distance 530 can be expressed as twice the sum of distance 524 and distance 528. In an illustrative example, distance 530 can be determined by the following formula: X3 = 2 * ((Y1 * tan a) (Y2 * tan (arc sine ((v2 / v1) * sine a))), where X3 represents the distance 530. The distance 530 and the third location 520 can be used to identify the first location 532.

Now referring to Fig. 6, an illustration of a structure inspection process according to an illustrative embodiment is depicted. The process illustrated in Figure 5 can be implemented using inspection equipment 206 of Figure 2. Additionally, this process can be implemented to inspect structure 208 for a number of inconsistencies 214 in Figure 2.

The process can begin by sending a signal to a structure at an angle of incidence from a transducer array (step 600). The signal can be directed to an angle of incidence by electronic time delay beam steering. The process can then detect a response signal in the transducer array to form a received response, the reflected response signal being sent from the structure at response to signal to structure (step 602). Then the process ends.

Now referring to Figure 7, an illustration of a block diagram of a data processing system according to an illustrative embodiment is depicted. The data processing system 700 may be an implementation of the controller 204 of FIG. 2. The data processing system 700 may be used to implement the identification of at least one of the number of dispatch items 230, the number of idle items 232 , and the number of receiving elements 234 of Figure 2. In some illustrative examples, the data processing system 700 can be used to control the send signals via the transducer array 220 of Figure 2. In this illustrative example, data processing system 700 includes communications framework 702, which provides communications between processor unit 704, memory 706, persistent storage 708, communication unit 710, input / output (I / O) unit 712 and display element 714. In this example, the communications framework 702 may take the form of a bus system.

Processor unit 704 serves to execute instructions for software that can be loaded into memory 706. Processor unit 704 can be a number of processors, a multi-processor core, or some other type of processor, depending on the particular implementation. .

Memory 706 and persistent storage 708 are examples of storage devices 716. A storage device is any piece of hardware that is capable of storing information, such as, for example, without limitation, data, program code in functional form, and / or other appropriate information either temporarily and / or permanently. Storage devices 716 may also be referred to as computer-readable storage devices in these illustrative examples. Memory 706, in these examples, can be, for example, random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 708 can take various forms, depending on the particular implementation.

For example, persistent storage 708 may contain one or more components or devices. For example, persistent storage 708 can be a hard disk, flash memory, rewritable optical disk, rewritable magnetic tape, or some combination of the above. The media used by persistent storage 708 can also be removable. For example, a removable hard drive can be used for 708 persistent storage.

Communications unit 710, in these illustrative examples, enables communications with other data processing systems or devices. In these illustrative examples, the communication unit 710 is a network interface card.

The input / output unit 712 allows data input and output with other devices that can be connected to the data processing system 700. For example, the input / output unit 712 can provide a connection for user input through a keyboard, mouse, and / or some other suitable input device. In addition, the input / output unit 712 can send the output to a printer. Display element 714 provides a mechanism for displaying information to a user.

Instructions for the operating system, applications, and / or programs can be located on storage devices 716, which are in communication with processor unit 704 through communications framework 702. The processes of the different embodiments can be performed by the unit of processor 704 using computer-implemented instructions, which can be located in a memory, such as memory 706.

These instructions are called program code, computer-usable program code, or computer-readable program code that can be read and executed by a processor in processor unit 704. The program code in the different embodiments can be included in different media. physical or computer-readable storage, such as memory 706 or persistent storage 708.

Program code 718 is located in a functional format on computer-readable media 720 that can be selectively extracted and can be uploaded or transferred to data processing system 700 for execution by processor unit 704. Program code 718 and Computer-readable media 720 forms computer program product 722 in these illustrative examples. In one example, computer-readable media 720 may be computer-readable storage media 724 or computer-readable signal media 726.

In these illustrative examples, computer-readable storage medium 724 is a physical or tangible storage device used to store program code 718 rather than a medium that propagates or transmits program code 718.

Alternatively, program code 718 may be transferred to data processing system 700 using computer-readable signal media 726. Computer-readable signal media 726 may be, for example, a propagated data signal containing program code 718 For example, computer-readable signal media 726 can be an electromagnetic signal, an optical signal, and / or any other suitable type of signal. These signals can be transmitted over communications links, such as communications links. wireless, fiber optic cable, coaxial cable, a cable, and / or any other suitable type of communication link.

The different components illustrated for data processing system 700 are not intended to provide architectural limitations as to how different embodiments can be implemented. The different illustrative embodiments may be implemented in a data processing system that includes components in addition to and / or in place of those illustrated for the data processing system 700. Other components shown in Figure 7 may be different from the illustrative examples shown. . The different embodiments can be implemented using any hardware device or system capable of executing the 718 program code.

Illustrative embodiments of the disclosure may be described in the context of the method of manufacturing and servicing aircraft 800 as shown in Figure 8 and aircraft 900 as shown in Figure 9. Referring first to Figure 8 , an illustration of an aircraft manufacturing and servicing method is depicted in block diagram form according to an illustrative embodiment. During pre-production, the aircraft manufacturing and servicing method 800 may include the specification and design 802 of the aircraft 900 in Figure 9 and the procurement of materials 804.

During production, the manufacturing of components and sub-assemblies 806 and the integration of the system 808 of the aircraft 900 in figure 9 are carried out. The aircraft 900 in figure 9 can then undergo certification and delivery 810 in order to be put into service 812. While in service 812 by a customer, the aircraft 900 of Figure 9 is scheduled for maintenance and service 814, which may include modification, reconfiguration, renovation and other maintenance or service.

Each of the processes of the aircraft manufacturing and servicing method 800 may be performed or carried out by a systems integrator, a third party, and / or an operator. In these examples, the operator can be a customer. For the purposes of this description, a systems integrator may include, without limitation, any number of aircraft manufacturers and major systems subcontractors; a third party may include, without limitation, any number of vendors, subcontractors and suppliers; and an operator can be an airline, a leasing company, a military entity, a service organization, and so on.

Now referring to Fig. 9, an illustration of an aircraft is shown in the form of a block diagram in which an illustrative embodiment may be implemented. In this example, the aircraft 900 is produced by the aircraft manufacturing and servicing method 800 of Figure 8 and may include the fuselage 902 with a plurality of systems 904 and the interior 906. Examples of systems 904 include one or more systems 908 propulsion system, 910 electrical system, 912 hydraulic system, and 914 environmental system. Any other number of systems may be included. Although an aerospace example is shown, different illustrative embodiments may apply to other industries, such as the automotive industry.

The apparatus and methods included herein may be employed during at least one of the steps of the aircraft manufacturing and servicing method 800 in Figure 8. One or more illustrative embodiments may be used during the fabrication of components and sub-assemblies 806. For example , the inspection kit 206 in FIG. 2 can be used during the manufacture of components and sub-assemblies 806. In addition, the inspection kit 206 can also be used to perform substitutions during maintenance and service 814. For example, spare parts for aircraft 900 can be inspected during scheduled maintenance of aircraft 900.

Thus, the different illustrative embodiments provide a method and apparatus for sending signals from an array of transducers at angles of incidence. In an illustrative example, signals can be sent from a transducer array at an angle of incidence using electronic time delay beam steering. In some illustrative examples, a number of inactive elements may receive response signals reflected by a number of inconsistencies in a structure.

Different illustrative embodiments can provide a method and apparatus for inspecting a structure in a reduced time. Different illustrative embodiments can provide a method and apparatus for inspecting a structure with increased sensitivity to debris or other foreign materials. Different illustrative embodiments can provide a method and apparatus for providing a higher signal-to-noise ratio in ultrasonic inspection using a transducer array.

Claims (10)

1. Method comprising: sending (600) an ultrasonic signal to a structure (208) at an angle of incidence (223) from an array of ultrasonic transducers (220); detecting (602) a response signal (242) in the array of ultrasonic transducers (220) to form a received response, the response signal (242) being reflected from the frame (208) in response to the ultrasonic signal sent to the frame (208); identifying a first location (236) of the array of ultrasonic transducers (220), wherein the first location (236) is an estimated receive location for a response signal (242) reflected from a rear surface of the structure (208 ); determining a second location (238) of the ultrasonic transducer array (220), wherein the second location (238) is an estimated receive location for a response signal (240) reflected by an inconsistency within the structure (208 ); configuring the array of ultrasonic transducers (220) so that the inactive elements (232) are located in the second location (238); Y configuring the number of inactive elements (232) to decrease an amplitude of the response signal (242) reflected from the rear surface of the structure (208) when the inconsistency is present. The method of claim 1, further comprising: configuring the array of ultrasonic transducers (220) so that the receiving elements (234) are located at the first location (236). The method of claim 1, further comprising: identifying an inconsistency within the structure (208) using the response signal (242). 4. The method of claim 3, wherein the inconsistency comprises foreign material within the structure (208). 5. The method of claim 1, wherein the structure (208) comprises a composite material. 6. The method of claim 1, wherein the structure (208) is comprised of a material selected from at least one of a metal, a composite material, a plastic, and a ceramic. 7. The method of claim 1, wherein the structure (208) is comprised of a plurality of layers of material (406). A method according to claim 1, wherein sending the ultrasonic signal to the structure (208) at the angle of incidence (223) from the array of ultrasonic transducers (220) comprises sending the ultrasonic signal to the structure (208 ) at the angle of incidence (223) of the array of ultrasonic transducers (220) using electronic time delay beam steering. 9. Apparatus comprising: an ultrasonic transducer array (220) comprising a plurality of elements (228); a number of sending elements (230) in the plurality of elements (228) configured to send an ultrasonic signal to a structure (208) at an angle of incidence (223); Y a number of receiving elements (234) in the plurality of elements (228) configured to detect a response signal (242) reflected from a rear surface of the structure (208), wherein the number of receiving elements (234) are located at a first location (236), wherein the first location (236) is an estimated receiving location for the response signal (242) reflected from the back surface of the structure (208); which also includes: a number of inactive elements (232) in the plurality of elements (228) located between the number of sending elements (230) and the number of receiving elements (234), wherein the number of inactive elements (232) is located at a second location (238), wherein the second location (238) is an estimated receive location for a response signal (240) reflected by an inconsistency within the structure (208), and wherein the number of inactive elements (232) is configured to decrease an amplitude of the response signal (242) reflected from the rear surface of the structure (208) when the inconsistency is present; Y further including a controller (204) arranged to configure each of the plurality of elements (228) of the transducer array (220) to be one of the number of sending elements (230), the number of inactive elements ( 232) or the number of reception elements (234). Apparatus according to claim 9, wherein the angle of incidence (223) is configured to decrease an amplitude of the response signal (242) reflected from the rear surface of the structure (208) when an inconsistency is present.